CN103635302A

CN103635302A - Method for forming resin molded product, and resin molded product

Info

Publication number: CN103635302A
Application number: CN201280032915.XA
Authority: CN
Inventors: 鹫见武彦
Original assignee: Kyoraku Co Ltd
Current assignee: Kyoraku Co Ltd
Priority date: 2011-07-14
Filing date: 2012-06-28
Publication date: 2014-03-12
Anticipated expiration: 2032-06-28
Also published as: KR20140015569A; US20150174799A1; KR101578593B1; CN103635302B; JP2013022734A; EP2732953A4; WO2013008633A1; US20160332343A1; EP2732953A1; JP6173657B2; US10668652B2; EP2732953B1

Abstract

Provided is a method for forming a resin molded product, the method being capable of improving the strength of fusion between a core material and resin sheets. A method for molding a resin molded product (100) by sandwiching and laminating a core material (102), which comprises a foamed body, between at least two molten resin sheets (101). The resin sheets (101) contain fibrous fillers. The core material (102) and the resin sheets (101) are fused together while the surfaces of the core material (102) are melted by the heat of the resin sheets (101), and the core material (102) and the resin sheets (101) are clamped together by dies to form the resin molded product (100).

Description

The manufacturing process of resin forming product and resin forming product

Technical field

The present invention relates to a kind of resin forming product to utilize mode that at least two resin sheets sandwich the core consisting of foaming body that resin sheet and core are laminated.

Background technology

As the technical literature of filing an application prior to the present invention, disclose the document of manufacturing process of the resin forming product that the mode that relates to utilizing two resin sheets to sandwich core is laminated resin sheet and core (for example, with reference to patent documentation 1:WO2009/157197, patent documentation 2: TOHKEMY 2011-51224 communique, patent documentation 3: TOHKEMY 2011-51227 communique).

In above-mentioned patent documentation 1～patent documentation 3, two sheet parisons (being equivalent to resin sheet) are supplied between assembling die, and the shape that this sheet parison figuration is formed for the die cavity along assembling die.Next, preshaped reinforcement core (being equivalent to core) is inserted between assembling die, reinforcement core is fused to a sheet parison.Next, assembling die matched moulds is fused to another sheet parison by reinforcement core, and makes the welding each other of sheet parison, thereby be shaped, will strengthen core and the integrated resin forming product forming of sheet parison.Thus, be shaped with the resin forming product that utilizes mode that two resin sheets sandwich core that resin sheet and core are laminated.

In addition, in above-mentioned patent documentation 1～patent documentation 3, owing to strengthening core and be fused to the sheet parison of the shape that figuration forms for the die cavity along assembling die, therefore, sometimes because assembling die turns cold sheet parison, easily solidify, thereby the heat seal strength of strengthening between core and sheet parison is reduced.

Consider above-mentioned situation, need to develop a kind of manufacturing process that can improve the heat seal strength between core and resin sheet.

In addition, at the patent documentation 4(TOHKEMY 2008-222208 communique as the technical literature of filing an application prior to the present invention) in, disclose and a kind of the lit-par-lit structure body that the first fibrous substrates, thermoplastic expanded sandwich layer and the second fibrous substrates are formed with the first fibrous substrates, thermoplastic expanded sandwich layer and this sequential cascade of the second fibrous substrates has been carried out to one compacting and the central layer that makes.

In above-mentioned patent documentation 4, fibrous substrates consists of the complexing nonwoven that contains fibrous material and resin binder, forms the fusing point of resinous principle of thermoplastic expanded sandwich layer higher than the fusing point of resin binder.Thus, even under the heating state when one is suppressed, also can be under the state of shape that stably keeps thermoplastic expanded sandwich layer, only make fibrous substrates resin binder partial melting and make fibrous substrates closely be engaged in the surface of thermoplastic expanded sandwich layer.

Patent documentation 1:WO2009/157197

Patent documentation 2: TOHKEMY 2011-51224 communique

Patent documentation 3: TOHKEMY 2011-51227 communique

Patent documentation 4: TOHKEMY 2008-222208 communique

In above-mentioned patent documentation 4, even with can be stably to keep the prerequisite that is shaped as of thermoplastic expanded sandwich layer under the heating state when one is suppressed, and do not make the melt surface of thermoplastic expanded sandwich layer yet.

Therefore, in the invention of above-mentioned patent documentation 4, it will also be appreciated that: even if the resin binder of partial melting fibrous substrates and make fibrous substrates closely be engaged in the surface of thermoplastic expanded sandwich layer only also likely exists the inadequate situation of heat seal strength between fibrous substrates and thermoplastic expanded sandwich layer.

Summary of the invention

The present invention considers above-mentioned situation and makes, and its object is to provide a kind of manufacturing process and resin forming product that can improve the resin forming product of the heat seal strength between core and resin sheet.

To achieve these goals, the present invention has following technical scheme.

the manufacturing process of resin forming product

The invention provides a kind of manufacturing process of resin forming product, this resin forming product is that the mode of utilizing at least two resin sheets of molten condition to sandwich the core consisting of foaming body is laminated this resin sheet and this core, it is characterized in that, above-mentioned resin sheet contains bat wool, this manufacturing process comprises following operation: welding operation, in this welding operation, Yi Bian utilize the heat of above-mentioned resin sheet to make the melt surface of above-mentioned core, Yi Bian by above-mentioned core and above-mentioned resin sheet welding; And forming process, in this forming process, by mould matched moulds, above-mentioned core and above-mentioned resin sheet are configured as to above-mentioned resin forming product.

resin forming product

The invention provides a kind of resin forming product, it is that the mode of utilizing at least two resin sheets to sandwich the core consisting of foaming body is laminated resin sheet and core, it is characterized in that, above-mentioned resin sheet contains bat wool, above-mentioned resin forming product by by melt surface above-mentioned core and the above-mentioned resin sheet welding of molten condition and lit-par-lit structure after integrated form.

Adopt the present invention, by making the resin sheet of molten condition contain bat wool, can suppress drawdown (Japanese: ドローダウ Application), therefore, can form in the mode of extrusion resin sheet at high temperature, thus can make more reliably core melt surface and by core and resin sheet welding.Its result, can improve the heat seal strength between core and resin sheet.In addition, by making resin sheet contain bat wool, can improve the rigidity of formed products.

Accompanying drawing explanation

Fig. 1 means the figure of structure example of the resin forming product 100 of present embodiment.

Fig. 2 means the figure for the schematic configuration example of the building mortion 60 of the resin forming product 100 of the present embodiment that is shaped.

Fig. 3 means the figure that makes frame member 128 be connected to the state of resin sheet P.

Fig. 4 means the figure that makes resin sheet P be connected to the state of assembling die 32.

Fig. 5 means the figure to the state after a resin sheet P figuration.

Fig. 6 means the figure that makes core 102 be fused to the state of a resin sheet P.

Fig. 7 means the figure to the state after another resin sheet P figuration.

Fig. 8 means the figure of the state after assembling die 32 matched moulds.

Fig. 9 means the figure of the state after assembling die 32 die sinkings.

Figure 10 mean in the time will utilizing assembling die 32 press-resin sheet P and core 102, the thickness A of resin sheet P is, the figure that is related to example between the degree of depth C of the thickness B of core 102 and assembling die 32.

The specific embodiment

the summary of resin forming product 100 of the present invention

First, the summary of resin forming product 100 of the present invention is described with reference to Fig. 1, Fig. 2, Fig. 6 and Fig. 8.Fig. 1 represents the structure example of an embodiment of resin forming product 100 of the present invention, and Fig. 2, Fig. 6 and Fig. 8 represent the example of manufacturing process of an embodiment of resin forming product 100 of the present invention.

As shown in Figure 1, resin forming product 100 of the present invention is resin forming products 100 that the mode of the core 102 that utilizes at least two resin sheets 101 to sandwich to consist of foaming body is laminated resin sheet 101 and core 102.

The resin sheet 101 that forms resin forming product 100 of the present invention contains bat wool.

When carrying out the shaping of resin forming product 100 of the present invention, for example, use the building mortion 60 shown in Fig. 2 to form, as shown in Fig. 6, Fig. 8, Yi Bian utilize the heat of resin sheet P to make the melt surface of core 102, Yi Bian by core 102 and resin sheet P welding.In addition, as shown in Figure 8, utilize mould 32 matched moulds and core 102 and resin sheet P are configured as to resin forming product 100.

Thus, can be shaped by by melt surface core 102 and the resin sheet P welding of molten condition and resin forming product 100 that lit-par-lit structure after integrated forms.

In addition,, when carrying out the shaping of resin forming product 100 of the present invention, because the resin sheet P of molten condition contains bat wool, therefore can suppress its drawdown.Thus, can be with extrusion resin sheet P at high temperature and form, thereby can make more reliably core 102 melt surface and by core 102 and resin sheet P welding.Its result, can improve the heat seal strength between core 102 and resin sheet P.

In addition, by making resin sheet P contain bat wool, can improve the rigidity of resin forming product 100.The embodiment of the resin forming product 100 that below, present invention will be described in detail with reference to the accompanying.

the structure example of resin forming product 100

First, the structure example of the resin forming product 100 of present embodiment is described with reference to Fig. 1.Fig. 1 means the figure of structure example of the resin forming product 100 of present embodiment.The resin forming product 100 of present embodiment for example can be used in the goods shelf plate (deck boat) of automobile.

The resin forming product 100 of present embodiment is stacked and form by resin sheet 101 and core 102 in the mode of the core 102 that utilizes resin sheet 101 to sandwich to consist of foaming body.

The core 102 consisting of foaming body forms the inner side part of resin forming product 100, and the main component of core 102 consists of phenylethylene resin series (more than at least containing 30wt%).By making the main component of core 102, be phenylethylene resin series, can improve its for example, rigidity under hot environment (being more than 90 degree).As phenylethylene resin series, can list acrylonitritrile-styrene resin (AS), acrylonitrile-butadiene-styrene copolymer (ABS), polystyrene (PS) and impact resistant polystyrene (HIPS) etc.

As core 102, can use the resin balls that contains blowing agent is filled in mould, and it is carried out foamable and the core that is shaped, by foaming, extrudes core being shaped etc.

As resin balls, (for example can list heat-resisting foaming polystyrene series resin balls, the カネパー Le (registration mark), ヒートマッ Network ス (registration mark) etc.) that the カネカ of Co., Ltd. (kaneka) manufactures, heat-resisting foaming polystyrene series resin balls low foaming and molding for (for example, the カネパー Le (registration mark), ヒートマッ Network ス (registration mark) HM5 etc.) of the カ of Co., Ltd. ネカ manufacture etc.In addition, can use the heat-resisting AS of foaminess is resin (for example, JSP Corp manufactures ヒートポー Le (registration mark)) etc.

As the core 102 with goods shelf plate as automobile, from light-weighted viewpoint, consider, preferably its expansion ratio is more than 15 times.In addition, as core 102, preferably also have heat resistance, particularly, preferably at the temperature of 80 ℃, the size changing rate through 168 hours is in ± 0.5%.

In addition, for the resin balls that forms core 102, preferably, the monomer that for example forms resin balls by the AMS (α of 10 % by weight～80 % by weight ?methylstyrene), acrylonitrile and the styrenic monomers below 85 % by weight of 5 % by weight～50 % by weight form, further preferably, by the AMS of 10 % by weight～50 % by weight, the acrylonitrile of 5 % by weight～35 % by weight, the styrenic monomers below 80 % by weight forms.So long as the combination in above-mentioned scope, heat resistance is compared with high and be suitable for the goods shelf plate of automobile.As styrenic monomers, can list the various substituted phenylethylenes such as styrene, chlorostyrene, p-methylstyrene (p-methylstyrene) and t-butyl styrene (t-butylstyrene).

In addition, in order to give anti-flammability to resin forming product 100, the resin balls that also can make core 102 use contains fire retardant.As bringing into play anti-flammability and can not make the fire retardant of heat resistance, foaminess variation, preferably its decomposition temperature is more than 210 ℃, and further preferably the fusing point of fire retardant is more than 80 ℃.As such fire retardant, can list halogen flame retardant, particularly, can list HBCD (hexabromocyclododecane), tetrabromobisphenol A (tetrabromobisphenol A), diallyl ether (diallyl ether) and a chlorine pentabromo-cyclohexane (モノ Network ロ Le ペ Application タ Block ロ system シ Network ロヘキサ Application) etc., wherein, be preferably HBCD.For the use amount of the fire retardant in resin balls, be preferably 1 % by weight～15 % by weight, more preferably 3 % by weight～10 % by weight.If use amount is less than 1 % by weight, be sometimes difficult to give anti-flammability, if use amount is greater than 15 % by weight, the tendency that exists heat resistance, foaminess to reduce.In addition, by above-mentioned fire retardant and with a small amount of flame retardant, can seek to improve anti-flammability.Flame retardant as with this end in view using, is used the free-radical generating agent such as peroxide conventionally, but in the present embodiment, as for bringing into play the desirable flame retardant of anti-flammability, is preferably 1 hour half life temperature at the flame retardant of 150 ℃～250 ℃.

Resin sheet 101 forms the outside of resin forming product 100, and is similarly also configured to and contains at least phenylethylene resin series more than 30wt% with core 102.Because the resin forming product 100 of present embodiment is configured to core 102 and resin sheet 101 all contains at least phenylethylene resin series more than 30wt%, therefore, can improve its for example, rigidity under hot environment (being more than 90 degree).

In addition, the resin sheet 101 of present embodiment is configured to and contains bat wool.The resin sheet 101 of present embodiment, owing to containing bat wool, therefore can improve rigidity.As bat wool, can list wollastonite, potassium titanate crystal whisker, glass fibre and carbon fiber etc., wherein, be preferably glass fibre, carbon fiber etc.

For the bat wool of present embodiment, the value that fibre length obtains divided by fibre diameter (draw ratio), in 250～2000 scope, especially, is considered from improving the viewpoint of formability and rigidity, preferably in 500～1200 scope.In addition,, in the situation that use the bat wool of glass, preferably its fibre length is that 8mm～20mm, fibre diameter are below 30 μ m.Its reason is, if fibre length is less than 8mm, the degree of the rigidity while improving heat resistance, high temperature by mixed fillers is less, if fibre length surpasses 20mm, is difficult to mix with substrate resin.In this case, especially, preferred resin sheet 101 contain with respect to resin sheet 101 be in (more preferably about 30 % by weight) in the scope of 20 % by weight～40 % by weight, fibre length is that 10mm～12mm, fibre diameter are the bat wool of the glass of about 14 μ m～17 μ m.

In addition, for the phenylethylene resin series that is used in core 102 and resin sheet 101, the fusing point of the phenylethylene resin series that the fusing point of the phenylethylene resin series that preferred resin sheet 101 is used is used higher than core 102.Thus, while can utilize the heat of the resin sheet 101 of molten condition to make the melt surface of core 102 by core 102 and resin sheet 101 weldings.

the example of the manufacturing process of resin forming product 100

Next, the example of manufacturing process of the resin forming product 100 of present embodiment is described with reference to Fig. 2～Fig. 9.Fig. 2 represents the structure example for the building mortion 60 of the resin forming product 100 of the present embodiment that is shaped, and Fig. 2～Fig. 9 means the figure of the forming process example that the resin forming product 100 of present embodiment is formed.

First, the structure example for the building mortion 60 of the resin forming product 100 of the present embodiment that is shaped with reference to Fig. 2 explanation.

The building mortion 60 of present embodiment be configured to there is extrusion device 12, mold closing mechanism 14 and core insertion apparatus (not shown).

The building mortion 60 of present embodiment is extruded two resin sheet P of molten condition from extrusion device 12, and two resin sheet P are disposed between the assembling die 32 that forms mold closing mechanism 14.Next, for the shape that the die cavity 116 along assembling die 32 forms, utilize core insertion apparatus (not shown) that the core after preshaped 102 is fused to a resin sheet P after this figuration a resin sheet P figuration.In addition, the shape that another resin sheet P figuration is formed for the die cavity 116 along assembling die 32, by assembling die 32 matched moulds, make core 102 be fused to another resin sheet P and by resin sheet P welding each other, thus the integrated resin forming product forming 100 of shaping core 102 and resin sheet P.

Extrusion device 12 is configured to be had: set up hopper 16 barrel (cylinder) 18, be arranged on the screw rod (not shown) in barrel 18, the electro-motor 20 being connected with screw rod, the accumulator 22 being connected with barrel 18, the plunger 24 being connected with accumulator 22 and T mould 28.

In the extrusion device 12 of present embodiment, melting, mixing under the effect of the rotation of the screw rod that the resin particle dropping into from hopper 16 drives at use electro-motor 20 in barrel 18, the resin (molten resin) of formation molten condition.Next, molten resin is transported to accumulator 22 and stores a certain amount ofly, then utilizes the driving of plunger 24 towards T mould 28 transporting molten resins, and from the resin sheet P that slit (not shown) is extruded continuous sheet that extrudes of T mould 28.

The resin sheet P that slit extrudes that extrudes from T mould 28 is opened pair of rolls 30 pressurizations of arranged spaced and downward sends and hang down between assembling die 32 by sky.Thus, resin sheet P with the state configuration that there is same thickness on above-below direction (extruding direction) between assembling die 32.

The plasticating capacity of extrusion device 12 is from size, the drawdown that prevents resin sheet P or the contracting width (Japanese: viewpoint ネッ Network イ Application) is considered and suitably selected of the resin forming product that will be shaped.Particularly, from practical viewpoint, consider, intermittently the extrusion capacity once spraying in extrusion is preferably 1kg～10kg, is preferably more than hundreds of kg/ hours, more preferably more than 700kg/ hour from the extruded velocity of extruding the resin sheet P of slit.In addition, from preventing the drawdown of resin sheet P or the viewpoint of contracting width, consider, the extrusion of preferred resin sheet P is as far as possible short, although this depends on kind, MFR value, the melting tension value of resin, but conventionally,, preferably extrusion completed with interior at 40 seconds, more preferably at 10 seconds～20 seconds, with interior, completed.

Therefore, certainly extrude the unit are (1cm of the thermoplastic resin that slit extrudes ²), the extrusion capacity of unit interval (h) is preferably 50kg/h cm ²above, 150kg/hcm more preferably ²above.For example, using density, be 0.9g/cm ³thermoplastic resin and from the slit of extruding of T mould 28, take and extrude thickness 15 seconds as 1.0mm, width are as 1000mm, while extruding the resin sheet P that the length in direction is 2000mm, once to spray (shot), in 15 seconds, extruded the thermoplastic resin of 1.8kg, can calculate extruded velocity is 432kg/ hour, and the extruded velocity of unit are is about 86kg/hcm ², the above-mentioned slit separation of extruding slit is 0.5mm, the length of slit on width is 1000mm.

In addition, the slit vertical of extruding of being located at T mould 28 configures downwards, certainly extrudes resin sheet P that slit extrudes directly down to be carried by vertical from extruding the form that slit hangs down.Extrude slit by making its variable spaced, thereby can change the thickness of resin sheet P.

But, preferably, the resin sheet P extruding from T mould 28 is adjusted, so that resin sheet P is under the state hanging down between assembling die 32, when carrying out matched moulds, at the even thickness of extruding in direction.In this case, also can make slit separation to increase gradually starting and to reach maximum mode while finishing and change extruding from extruding.Thus, although the thickness of the resin sheet P extruding from T mould 28 from extrude start thickening gradually, but because the resin sheet P extruding with molten condition is stretched under Gravitative Loads from below sheet towards above attenuation gradually, therefore, increase slit separation and thicken the amount of extruding the amount of attenuate is cancelled out each other with being stretched under the effect of drawdown phenomenon, thereby can in the gamut of below, resin sheet P be adjusted into uniform thickness from the top of sheet.

In the building mortion 60 of present embodiment, by utilizing the rotation of pair of rolls 30, the resin sheet P being sandwiched between pair of rolls 30 is sent downwards, thereby can make resin sheet P extend and thin-walled property, by the relation between the rate of delivery of the resin sheet P that adjusts the extruded velocity of the resin sheet P extruded by T mould 28 and sent by pair of rolls 30, can prevent drawdown or the contracting width of resin sheet P.Therefore, can alleviate the kind of adopted resin, the especially quantitative limitation of extruding to MFR value, MT value, unit interval.

Pair of rolls 30 is configured to respect to be line symmetry from extruding the resin sheet P that form that slit hangs down is extruded downwards.The diameter of roller 30 and roller 30 length in the axial direction are suitably set accordingly with the extruded velocity of the resin sheet P that will be shaped, length, the width of resin sheet P, the kind of resin etc. extruding in direction of resin sheet P.In addition, on pair of rolls 30 outer surface separately, be provided with concavo-convex fold (Japanese: シボ).Preferably, concavo-convex fold is arranged on the outer surface of roller 30 in equally distributed mode on contact with resin sheet P at roller 30 whole, the degree of depth, density for fold, as long as consider and produce this point and it is carried out suitably setting of sliding between the surface that does not make pair of rolls 30 outer surface separately and corresponding resin sheet P, to can utilize pair of rolls 30 that resin sheet P is sent swimmingly downwards.In addition, concavo-convex fold for example can utilize blasting treatment to form, but preferably, adopts the shot-peening of the granularity of No. 60 left and right to form fold in sand-blasting machine.

In addition, the concavo-convex fold being separately positioned in pair of rolls 30 is not for the surface transfer pleated pattern to resin sheet P arranges, but to slide and arrange in order to prevent from producing between the surface of pair of rolls 30 outer surface separately and corresponding resin sheet P.

When the surface transfer pleated pattern to resin sheet P, conventionally using a roller in pair of rolls 30 as fold roller, using another roller as rubber rollers, but in the pair of rolls 30 of present embodiment, by fold being set on pair of rolls 30 outer surface separately, by making pair of rolls 30, control reliably separately the surface corresponding with pair of rolls 30 of resin sheet P, limit on the other hand the pressing force of 30 couples of resin sheet P of pair of rolls, thus, can be not do not utilizing pair of rolls 30 just pleated pattern to be transferred on the surface of resin sheet P at once after sending resin sheet P.

Pair of rolls 30 be metal, be for example aluminum, in pair of rolls 30, all set up surface temperature adjustment component, this surface temperature adjustment component is for adjusting the surface temperature of roller 30 according to the temperature of the resin sheet P of molten condition, the formation of this surface temperature adjustment component is, by cold-producing medium being passed into the inside of roller 30 and making this refrigerant circulation, thereby carry out heat exchange, to do not make the surface of roller 30 by the resin sheet P superheated of the molten condition being sandwiched by pair of rolls 30.

When the outer surface of pair of rolls 30 leads to heat transfer because pair of rolls 30 contacts with the resin sheet P of molten condition and is heated, the outer surface of cooling pair of rolls 30 from inner side, can prevent following situation thus,, the resin sheet P of the molten condition being sandwiched by pair of rolls 30 is attached on the outer surface of roller 30, because the rotation of roller 30 is wound on roller 30, resin sheet P can not be sent downwards.In this case, from the viewpoint that prevents from reeling, consider, preferably make the surface temperature of roller 30 lower, but afterwards, from the viewpoint of shaping resin sheet P, consider, if make the surface temperature of roller 30 too low, the surface of roller 30 on the contrary can be by the resin sheet P sub-cooled of molten condition, thereby can when being shaped, produce obstacle.Therefore, need to set pair of rolls 30 surface temperature separately in the mode in the scope of the low set point of temperature of temperature of the resin sheet P of the molten condition than extruding towards pair of rolls 30.The scope of this set point of temperature is correspondingly determined according to the kind of the resin sheet P of molten condition.In this case, for the surface temperature of pair of rolls 30 is carried out to temperature adjustment, when water-cooled is carried out in pair of rolls 30 inside separately, can according to the kind of resin sheet P, correspondingly set the temperature of cold-producing medium, in the process of shaping resin sheet P, the temperature of cold-producing medium is remained on to steady temperature.

The mold closing mechanism 14 of present embodiment is configured to has assembling die 32 and die drive unit (not shown), this die drive unit make assembling die 32 along and the direction of the supply of resin sheet P roughly the direction of quadrature between open position and closing position, move.

Assembling die 32 is so that the relative state configuration of die cavity 116, and each die cavity 116 is to configure towards the mode of vertical roughly.On the surface of die cavity 116, profile and the corresponding mode of surface configuration of the formed products forming with the resin sheet P with based on molten condition are provided with jog.In addition, the surrounding at the die cavity 116 of assembling die 32 is formed with embryo (pinch off) portion 118 of cutting.This is cut embryo portion 118 and is formed in the form of a ring die cavity 116 around, and outstanding towards relative assembling die 32.Thus, when by assembling die 32 matched moulds, can make each leading section of cutting embryo portion 118 connect and form die parting line at the periphery of formed products.

In addition, between assembling die 32, dispose frame member 128.Frame member 128 has opening 130, utilizes not shown frame member driving device and frame member 128 is moved towards resin sheet P, and frame member 128 and resin sheet P are connected, thereby keeps resin sheet P.In addition, make frame member 128 under the state that is keeping resin sheet P to mobile and the front end of cutting embryo portion 118 of resin sheet P and assembling die 32 is connected in the other direction, thereby by resin sheet P, cut embryo portion 118 and die cavity 116 forms confined space.

Assembling die 32 is driven by die drive unit (not shown), when assembling die 32 is in an open position, can between assembling die 32, configure the resin sheet P of molten condition.In addition, when assembling die 32 is in the close position, the mutual butt of the embryo portion of cutting 118 of assembling die 32 and at the interior formation confined space of assembling die 32.In addition, for the movement from open position to closing position of each assembling die 32, closing position is the residing position of center line of the resin sheet P of molten condition, and each assembling die 32 is driven by die drive unit and moves towards this position.

Resin sheet P is configured to using phenylethylene resin series as main component.From preventing the viewpoint that produces wall unevenness because of drawdown, contracting width etc., consider, preferably the resin sheet P of present embodiment is used the higher phenylethylene resin series of melting tension force, in addition, good with respect to transfer printing, the tracing ability of assembling die 32 in order to make, preferably use the phenylethylene resin series that mobility is higher.

For the phenylethylene resin series that is used in resin sheet P, MFR(when it can apply 230 ℃ measures under the condition of 230 ℃ of test temperatures, test load 2.16kg according to JIS K-7210) be the phenylethylene resin series below 3.5g/10 minute.If MFR is greater than 3.5g/10 minute, drawdown becomes violent and the formed products of the thin-walled that is difficult to be shaped.

In addition, the resin sheet P of present embodiment is configured to and contains bat wool in order to have heat resistance and rigidity.Thus, even after T mould 28 extrusion resin sheet P, the temperature that also can suppress resin sheet P reduces.In addition, though for example, under high temperature (being more than 210 degree) from T mould 28 extrusion resin sheet P, also can suppress the impact of drawdown.Conventionally, when for example, at the lower extrusion resin sheet P of high temperature (being more than 210 degree), drawdown becomes and is significantly difficult to be shaped, but by making resin sheet P contain bat wool, can suppress the impact of drawdown.In addition, in the present embodiment, owing to utilizing the heat of resin sheet P to make the melt surface of core 102, therefore, preferably the temperature of the resin sheet P when T mould 28 extrusion resin sheet P is more than 210 degree, more preferably more than 250 degree.Therefore,, in order to suppress the impact of drawdown, in the resin sheet P of present embodiment, contain bat wool.

In addition, for the resin sheet P of present embodiment, from the viewpoint of thin-walled property and raising rigidity, consider, also can further add the inorganic filler of the powderies such as silica, mica, talcum and calcium carbonate.But, if the interpolation quantitative change of inorganic filler is many, can make the surface of formed products produce be full of cracks (Japanese: waste れ), and easily produce pin hole (pinhole).Therefore,, in order to suppress the surperficial be full of cracks of formed products and to make it be difficult for producing pin hole, preferred added inorganic filler is less than 30 % by weight.

In addition, also can in resin sheet P, add plasticizer, stabilizing agent, colouring agent, antistatic additive, fire retardant and blowing agent etc.

Next, the forming process example of the resin forming product 100 of present embodiment is described with reference to Fig. 2～Fig. 9.

First, as shown in Figure 2, from T mould 28 extrusion resin sheet P, the resin sheet P after this is extruded, by adjusting the wall thickness of resin sheet P between pair of rolls 30, then makes resin sheet P hang down between pair of combined moulds tool 32.

In the building mortion 60 of present embodiment, the relative speed difference that the rotating speed that utilizes pair of rolls 30 is sent downwards the extruded velocity of resin sheet P and pair of rolls 30 between the rate of delivery of resin sheet P is adjusted, when resin sheet P passes through between pair of rolls 30, it is drop-down by pair of rolls 30, can make thus resin sheet P extend and thin-walled property, its result, can prevent drawdown or contracting width.

In this case, by concavo-convex fold being set on pair of rolls 30 surface separately and in one end of roller 30, gear mechanism being set, thereby the rotary driving force that rotarilys actuate roller 30BA is passed to and is driven in rotation roller 30BB, and the rotary driving force that rotarilys actuate roller 30AA is passed to and is driven in rotation roller 30AB, and do not make to rotarily actuate roller 30A and be driven in rotation, between roller 30B, do not produce speed discrepancy, thus, prevent from producing fold or shearing traces on the surface of resin sheet P.

In addition, by making cold-producing medium in pair of rolls 30 inner loop separately, thereby by roller 30 cooling and with the low mode of the temperature of the resin sheet P than molten condition by the Temperature Setting of roller 30 outer surface separately in the scope of set point of temperature, when the resin sheet P of molten condition is sandwiched by pair of rolls 30, the resin sheet P that can prevent molten condition is attached on the surface of roller 30, prevent from because of the rotation of roller 30, resin sheet P being wound on roller 30, thereby resin sheet P is remained to molten condition applicable while being shaped.

In addition, also can adjust the rotating speed of pair of rolls 30 and the interval of extruding slit in the mode of interlock.

After resin sheet P is configured between assembling die 32, utilize frame member driving device (not shown) that frame member 128 is moved towards resin sheet P corresponding thereto, as shown in Figure 3, frame member 128 and resin sheet P are connected, to utilize frame member 128 to keep resin sheet P.

Next, frame member 128 is moved towards assembling die 32, as shown in Figure 4, the embryo portion 118 of cutting of resin sheet P and assembling die 32 is connected, by resin sheet P, cut embryo portion 118 and die cavity 116 forms confined space 117.In addition, as shown in Figure 4, the core 102 that the sucker 119 by executor (not shown) is being kept is inserted between assembling die 32.

Next, see through in 32 pairs of confined spaces 117 of assembling die and aspirate, a resin sheet P is pressed to die cavity 116, thus, as shown in Figure 5, the shape by a resin sheet P figuration for forming along die cavity 116.

In addition, executor is moved towards the assembling die 32 on right side, as shown in Figure 6, core 102 is pressed on to a resin sheet P on the die cavity 116 of the assembling die 32 that is attracted to right side, thereby core 102 is fused to a resin sheet P.

Because the resin sheet P of present embodiment consists of phenylethylene resin series and contains bat wool, therefore, even after resin sheet P figuration is the shape of die cavity 116, also can maintain the state of temperature of the degree of the melt surface that makes core 102.Therefore,, when core 102 is pressed on to resin sheet P, can utilize the heat of resin sheet P to make the melt surface of core 102.Its result, in the present embodiment, while can utilize the heat of resin sheet P to make the melt surface of core 102 that core 102 is fused to resin sheet P.

Next, make sucker 119 depart from core 102, executor is extracted out between two assembling dies 32, and another resin sheet P is pressed to die cavity 116, thus, as shown in Figure 7, the shape by another resin sheet P figuration for forming along die cavity 116.

Next, utilize die drive unit by two assembling die 32 matched moulds, as shown in Figure 8, core 102 is pressed on to another resin sheet P on the die cavity 116 of assembling die 32 that is attracted to left side, thereby core 102 is fused to another resin sheet P.In addition, the periphery of two resin sheet P phase welding form die parting line PL each other.

In addition, because the surface of the core 102 of present embodiment is by the heat melting of resin sheet P, therefore, preferably, by assembling die 32 matched moulds, while being shaped by core 102 and the integrated resin forming product 100 forming of resin sheet P, utilize assembling die 32 compression core 102 and resin sheet P.Thus, can further improve the heat seal strength between core 102 and resin sheet P.

For example, as shown in figure 10, when the thickness A that forms two resin sheet P of resin forming product 100 being made as to A=1mm, the thickness B of core 102 is made as to B=15mm, preferably the degree of depth C of the die cavity of assembling die 32 116 is made as to C=8mm, core 102 and resin sheet P are compressed altogether to 1mm left and right.In this case, the width 2C of the confined space forming during by assembling die 32 matched moulds is 2C=16mm, the thickness of core 102 and two resin sheet P adds up to 2A+B=17mm, and therefore, the resin forming product 100 forming through assembling die 32 matched moulds is compressed respectively 0.5mm by each assembling die 32.Thus, be easy to the bat wool containing in resin sheet P to be pressed into core 102, thereby can make the welding between resin sheet P and core 102 firm, and the higher resin forming product 100 of the rigidity that can be shaped.In addition,, when utilizing assembling die 32 to compress, preferably utilize each assembling die 32 to compress in the scope of 0.5mm～1.0mm left and right.

By above operation, completed the resin forming product 100 that core 102, resin sheet P are laminated.

Next, as shown in Figure 9, by two assembling die 32 die sinkings, make the resin forming product 100 after die cavity 116 has left and remove the burr of the surrounding that is formed on die parting line PL.In sum, completed the shaping of resin forming product 100.

effect, the effect of the resin forming product 100 of present embodiment

As mentioned above, the resin sheet 101 of the resin forming product 100 of formation present embodiment contains bat wool.And, as shown in Fig. 6, Fig. 8, when carrying out the shaping of resin forming product 100, Yi Bian utilize the heat of the resin sheet P of molten condition to make the melt surface of core 102, Yi Bian by core 102 and resin sheet P welding.And, as shown in Figure 8, by assembling die 32 matched moulds, core 102 and resin sheet P are configured as to resin forming product 100.

When the shaping of resin forming product 100 of carrying out present embodiment, because the resin sheet P of molten condition contains bat wool, therefore can suppress drawdown.Thus, can form in the mode of extrusion resin sheet P at high temperature, thus can make more reliably core 102 melt surface and by core 102 and resin sheet P welding.Its result, can improve the heat seal strength between core 102 and resin sheet P.In addition, by making resin sheet P contain bat wool, can improve the rigidity of resin forming product 100.

In addition, due to for forming the core 102 of resin forming product 100 of present embodiment and resin sheet P all using phenylethylene resin series as main component, therefore, can further improve the rigidity of resin forming product 100 and the heat seal strength between core 102 and resin sheet P.

In addition, above-mentioned embodiment is the preferred embodiment of the present invention, scope of the present invention only should be defined as to above-mentioned embodiment, can to have carried out the mode of various variations, implement the present invention without departing from the spirit and scope of the invention.

For example, in the manufacturing process of above-mentioned embodiment, as shown in Figure 4, make resin sheet P be connected to the embryo portion 118 of cutting of assembling die 32, by resin sheet P, cut after embryo portion 118 and die cavity 116 form confined space 117, core 102 is inserted between assembling die 32.But, can be also, by resin sheet P from T mould 28 to before extruding between assembling die 32, in advance core 102 is inserted between assembling die 32.The surface that thus, can utilize the heat of the resin sheet P extruding from T mould 28 to heat in advance core 102.

In addition, in the manufacturing process of above-mentioned embodiment, two resin sheet P are being configured between assembling die 32, afterwards, make core 102 successively with this two resin sheet P phases welding.But, can be also, on one side by two resin sheet P be disposed at respectively assembling die 32 make on one side core 102 successively with the welding of two resin sheet P phases.Particularly, first, a resin sheet P is disposed to assembling die 32, the shape that this resin sheet P figuration is formed for the die cavity 116 along assembling die 32, and make core 102 be fused to this resin sheet P.Then, another resin sheet P is disposed to assembling die 32, the shape that this resin sheet P figuration is formed for the die cavity 116 along assembling die 32, and make core 102 be fused to this resin sheet P.Thus, can shorten the time that makes core 102 and the resin sheet P phase welding of extruding from T mould 28, therefore can utilize the heat of resin sheet P to make the surface of core 102 be easy to melting.

In addition, in above-mentioned manufacturing process, core 102 is not applied to heat treated, while but utilize the heat of resin sheet P to make the melt surface of core 102 that core 102 is fused to resin sheet P.But, in above-mentioned manufacturing process, can be also, before core 102 is inserted between assembling die 32, the surface of using the heater blocks such as infrared heater to heat in advance core 102.

In addition, also can be, a resin sheet P on the die cavity 116 that as shown in Figure 6 core 102 is pressed on to the assembling die 32 that is attracted to right side and make before core 102 is fused to a resin sheet P, to utilize heater block to heat in advance the surface of core 102.

In addition, also can be, as shown in Figure 8 core 102 being pressed on to another resin sheet P on the die cavity 116 of assembling die 32 that is attracted to left side, make before core 102 is fused to another resin sheet P, to utilize heater block to heat in advance the surface of core 102.

That is, can be also, before by resin sheet P and core 102 weldings, to utilize the surface of heater block heating core 102 and make in advance the melt surface of core 102.

In addition, as long as utilize the surperficial opportunity of heater block heating core 102, be before by resin sheet P and core 102 weldings, be not particularly limited, can be on the surface of heating core 102 opportunity arbitrarily.

In addition, in the above-described embodiment, can be also, decoration material tablet is configured between assembling die 32, utilize the matched moulds of assembling die 32 that decoration material tablet is fused to resin sheet P.In addition, can be also, decoration material tablet is supplied between pair of rolls 30 together with resin sheet P, by adjusting the rotating speed of pair of rolls 30, adjust the thickness of resin sheet P and decoration material tablet is crimped on to resin sheet P.

In addition, the resin forming product 100 of above-mentioned embodiment is that the mode of utilizing two resin sheet P to sandwich core 102 is shaped.For example, but the resin forming product 100 of present embodiment, as long as form in the mode of utilizing at least two resin sheet P to sandwich core 102,, also can form in the mode of utilizing 4 resin sheet P to sandwich core 102.The layer structure of resin forming product 100 is now resin sheet/resin sheet/core/resin sheet/resin sheet.

description of reference numerals

100, resin forming product; 102, core; 101, P, resin sheet; 60, building mortion; 12, extrusion device; 14, mold closing mechanism; 16, hopper; 18, barrel; 20, electro-motor; 22, accumulator; 24, plunger; 28, T mould; 30, roller; 32, assembling die; 128, frame member; 130, opening; 116, die cavity; 118, cut embryo portion.

Claims

1. a manufacturing process for resin forming product, this resin forming product is that the mode of utilizing at least two resin sheets of molten condition to sandwich the core consisting of foaming body is laminated this resin sheet and this core, it is characterized in that,

Above-mentioned resin sheet contains bat wool,

This manufacturing process comprises following operation:

Welding operation, in this welding operation, Yi Bian utilize the heat of above-mentioned resin sheet to make the melt surface of above-mentioned core, Yi Bian by above-mentioned core and above-mentioned resin sheet welding; And

Forming process, in this forming process, is configured as above-mentioned resin forming product by mould matched moulds by above-mentioned core and above-mentioned resin sheet.

2. the manufacturing process of resin forming product according to claim 1, is characterized in that,

Above-mentioned core and above-mentioned resin sheet contain phenylethylene resin series.

3. the manufacturing process of resin forming product according to claim 1 and 2, is characterized in that,

In above-mentioned forming process, by utilizing above-mentioned mould to carry out matched moulds, can be by above-mentioned core and the compression of above-mentioned resin sheet.

4. a resin forming product, it is that the mode of utilizing at least two resin sheets to sandwich the core consisting of foaming body is laminated this resin sheet and this core, it is characterized in that,

Above-mentioned resin sheet contains bat wool,

Above-mentioned resin forming product by by melt surface above-mentioned core and the above-mentioned resin sheet welding of molten condition and lit-par-lit structure after integrated form.

5. resin forming product according to claim 4, is characterized in that,